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Do you know the similarities between cables and wires? Wires and cables are very similar in nature and they can have similar purposes.

The Main Similarities

The main similarities between cables and wires are that they both conduct electrical currents. Wires are the components of a cable. Multiple wires make up a single cable. Also, a single wire and a single cable both can have insulation or insulative jackets. However, a cable has an outer jacket while the single wires inside have their jackets as well. The differences in insulation can determine the different uses of a wire and cable.

Cables Cables

As stated previously, cables consist of multiple wires. There are cables that have the wires twisted to hold them together. There are also some that have the separate wires encased in an insulated jacket. This jacket doesn’t just hold the internal wires together but it also protects the internal wires from the elements. Cables can also contain numerous insulated wires. There is an extra level of protection when individual wires within a cable have their own insulation.  There is protection from corrosion and friction amongst individual wires due to the extra insulation.

Wires 

Solid and stranded are the two types of wires. Many individual strands of wire twisted together make up stranded wires. These strands can be very fine or larger depending on the application. Generally, the more strands and the smaller the strands the more flexible the wire is. Solid wire is just that, one strand of copper drawn to the appropriate gauge size. Also, wires can either be insulated or non-insulated. Insulted wires are less likely to have corrosion or the added issue of contact between non-insulated wires. A number of different applications use non-insulated wires. These applications include places where electrical wiring, armature wire, and magnet wire are needed. Non-insulated wiring is different from the insulated wire. This is due to it not being plated or coated with anything.

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Wire Harness Estimate

Introducing the FEI Wire Harness Estimator

Falconer Electronics, Inc (FEI) proudly announces launching the brand new FEI Wire Harness Estimator. Our team is extremely excited to share this new tool with customers: https://falconerelectronics.com/custom-wire-harness-estimator/

Especially those who are eager to capture an estimate or ballpark price on their Wire Harness Assembly quickly and easily. Below offers a step by step process when using the FEI Wire Harness Estimator. 

Steps to Complete the FEI Wire Harness Estimator

 

Step 1 – Select Wire Type 

FEI Wire Harness Estimator

SELECT YOUR UNCUT WIRE (or wires): 

You may select multiple wires – Click “Add to Estimate” after each selection 

Options include:

Wire Stranded

  • Available Colors – Black, White, Green, Red, Blue, Yellow, Brown
  • Available Gauges – 6, 8, 10, 12, 14, 16, 18, 20, 22  

Flexible Ground Braid 

  • Uninsulated  
  • 1/4″ and 1/2″ 

Ribbon Cable – Gray 

  • Available Color – Gray or Color-coded 
  • Conductor – 10, 14, 16, 20, 26, 40 

THHN – Solid 

  • Available Color – Black, White, Green, Red, Gray, Orange 
  • Available Gauge – 12 Gauge Only 

THHN – Strand 

  • Available Colors – Black, White, Green 
  • Available Gauge – 12 Gauge Only 

Select Length – The TOTAL length of wire required for a single assembly – This also applies for multiple wires. Select the length of each wire. 

Click “ADD TO ESTIMATE” 

The Estimator allows you to Add multiple wires.

Review your selection – if ready to proceed – click “NEXT STEP”

 

STEP 2 – Select the Number of Individual Wires 

 

Wire Harness Estimator

This section will include the TOTAL number of Individual Wires in your wire harness assembly

Click “NEXT STEP”

 

STEP 3 – Select Your Terminal 

Wire Harness Estimator

This section allows you the opportunity to select a specific manufacturer part number. Enter the manufacturer part number in the space provided and hit SEARCH. The product will populate into the estimate. 

If your specific part number is not available, you may select from the list of “house” parts below: 

  • Ring Terminal
  • Fork Terminal
  • Quick Connect/Disconnect Terminals
  • Ferrules Terminal

Select Quantity (for a Single Wire Harness) 

Click “ADD TO ESTIMATE” 

You may add multiple terminals and hit “ADD TO ESTIMATE” each time

Click “NEXT STEP” 

 

STEP 4 – Select Add-ons 

 

Wire Harness Estimator

 

  • Spiral Wrap
  • Expandable Sleeving 
  • Wire Ties 
  • Heat Shrink
  • Wire Labels 
  • Wire Label Flags 

Enter Length in inches 

Click “ADD TO ESTIMATE” 

You may add multiple Add-ons in this section. Please hit “ADD TO ESTIMATE” after each selection. 

Click “NEXT STEP” 

 

STEP 5 – Component Request 

 

Wire Harness Estimator

This section allows you the opportunity to add any additional components or helpful notes to help determine your estimate. 

Any items added to the “Components Request” section will NOT be added to the initial estimate. You will receive a separate email including the additional components to your wire harness assembly estimate. 

 

STEP 6 – Review and Submit 

Wire Harness Estimator

 

The Summary page allows you the opportunity to review your entries and make sure that everything looks accurate. 

Once you are satisfied with your selection simply enter your name and email address. You may also enter a project number to help keep track of each wire harness assembly estimate. 

Enter the correct number for the captcha and hit SUBMIT. 

You will receive your estimate within seconds in your email box. 

 

Questions

Please call 716-665-4176 at any step of the process with questions from 7-3:30 EST or email [email protected] 

We are excited to offer this new program and welcome your constructive feedback. 

To learn more about these exciting products please connect on FacebookTwitterGoogle+, and LinkedIn,.

Matchmaking Wires & Wire Terminals

Wires get lonely! They like to socialize and maintain good company just like the rest of us (most of the time anyway). Good-hearted wires need healthy companionship with wire terminals. For example, a nice looking wire terminal from a family of good character typically make a great match for our wires. Excellent work ethic is another necessary trait. 

After building wire harness assemblies for over 30+ years, the team at Falconer Electronics likes to claim themselves as expert matchmakers of wires and wire terminals. We match wire and terminals safely and accurately. Wires need a terminal that is strong, loyal, hard-working and dedicated. Another requirement: Wire terminals that give great hugs. Holding on super tight to their wire companions is mandatory! 

In other words, a terminal that is committed to a long-term relationship. Short-term flings or a one-night stand simply does not fly around here. We only match wires and terminals that fit as soulmates. Life partners that fight through thick and thin.

Just look at all of these happy love birds that were recently matched up:

Wire Terminals

Wire Terminals at Falconer Electronics

Types of Wire Terminals 

A terminal establishes an electrical connection by terminating a conductor or wire. When matching the right wire with the best terminal, there are several factors to consider: Wire gauge, screw or stud size, as well as the electric throughput. Therefore, it is critical that the wire and terminal can handle the measure of electricity. 

Various types of terminals include: Ring terminals –  Fork terminals – Hook terminals – Spade terminals – Insulated and Non-insulated

Insulation on a terminal provides extra protection against extreme hot or cold temperatures.  The insulation on the terminal also helps prevent dust particles or debris from creating havoc within the connection. Lastly, the insulation will serve as a protector against corrosion or moisture from having a negative impact on the connection.  

Wire Terminals

Looking for a seasoned matchmaker of wire and wire terminals? Please contact us at your earliest convenience. We Love playing cupid! 

Look each week for our “Wire Harness Wednesday” blog posts. Also, check out our blog series on LED lighting every Friday for the month of June. Follow us on Facebook, Twitter, Google+, LinkedIn and Pinterest for more electronic info.